BMW R 1100 GS + Adventure User manual

BMW Motorcycle

After Sales

R 1100 RT

R 1100 RS

R 850/1100 GS

R 850/1100 R

Repair Manual

Published by: © BMW Motorcycle

After Sales

UX-VS-2

permission.

Errors and omissions excepted; subject to technical amendment.

Produced in Germany 02/00

Introduction

This repair manual will help you to perform all the main maintenance and repair work correctly and efficient-

ly. It should be consulted regularly by workshop personnel as an addition to the practical and theoretical

knowledge obtained in Training School courses. It is a contribution towards achieving even higher Service

quality.

All information in both text and illustrations refers to motorcycles in standard condition or with genuine

BMW accessories installed, and not to motorcycles which have been modified in any way to depart from

the manufacturer’s specification.

● The repair manual is structured in the logical sequence of the work to be performed: Removal, Dis-

assembly, Repair, Assembly, Installation.

● The entire contents are divided into individual chapters, corresponding to the Construction Groups.

11 . 10

Chap. Page number within chapter

● Work to be performed during an Inspection is described in Group “00”. The various inspection routines

are numbered I, II, III and IV. This numbering is repeated in the work descriptions which follow, so that

work can take place without interruption.

● Use of the BMW special tools needed for certain tasks is described in the work instructions.

If the need arises, repair instructions are also issued in the form of Service Information. This information is

of course incorporated into the next issue of the repair manual. We also recommend you to consult the

detailed illustrations on the Parts microfiches as an additional source of information.

BMW Motorcycle

After Sales

Published by: BMW Motorrad

Hufelandstr. 6

D - 80937 München

permission.

Errors and omissions excepted; subject to technical amendment.

Produced in Germany

00 Maintenance and general instructions

11 Motor

12 Engine electrics

13 Fuel preparation and control

16 Fuel tank and lines

18 Exhaust system

21 Clutch

23 Gearbox

31 Front fork

32 Steering

33 Rear wheel drive

>> Continuation

Contents

<< Back

Group / Chapter

34 Brakes

36 Wheels and tyres

46 Frame

51 Equipment

52 Seat

61 General electrical equipment

62 Instruments

63 Lights

<< Back

>> Continuation

Group / Chapter

Order No. 01 71 7 654 296 UX-VS-2, 03.99 Printed in Germany

Customer Registration No.

Order No. Signature of mechanic

BMW Inspection

1000 km/ 600 mls

BMW Service

10 000 km/6000 mls

BMW Inspection

20 000 km/12 000 mls

BMW

Annual Service

Change engine oil when engine is warm, renew oil filter cartridge

1)

Change oil in manual transmission and rear wheel drive when at operating temperature

Retighten cylinder head nuts

Adjust valve clearance

Check spark plugs

Renew spark plugs

Renew fuel filter

3)

*

)

Check battery acid level, if necessary top up with distilled water

Clean and grease battery terminals

Renew intake air cleaner

2)

Check throttle cables for free movement, abrasion and kinking,

renewing if necessary *

)

Check clutch clearance, adjust if necessary

Adjust Poly-V-belt [b SI 12 020 95 (700)]

4)

5)

Retighten hose clips at intake pipe

Check brake pads and discs for wear, renew if necessary *

)

Check front/rear brake fluid level, top up if necessary *

)

[b SI 00 027 95 (716)]

Check brake system with regard to function, leaks; repair/renew as required *

)

Renew brake fluid at least once a year

Check wheel bearings, renew if necessary *

)

Check swinging arm bearing (no play), adjust if necessary *

)

Check steering damper (R850/1100R)

Lubricate side stands, centre stand (R 1100 RS) and nipple for clutch cable assembly

Check side stand switch for damage and correct operation [b SI 46 033 96 (722)]

Check fit of rear wheel bolts

Check bolts of control arm to specified torque

Clean and grease shaft for windshield adjustment (R 1100 RS)

Grease lower eye of front spring strut (R 1100 RS slide bearing)

Check idle speed, throttle synchronisation and CO value, adjust if necessary

Final inspection with safety/operating check:

– condition of tyres and wheels, rims and spokes, tyre pressures

– lights and signal systems

– telltale and warning lights

– clutch and gear shift

– handbrake and footbrake, steering

– instruments

– test ride, if necessary

1)

for short-distance driving or outside temperatures below 0°C every 3 months, every 3,000 km (1,800 miles) at the latest

2)

in very dirty or dusty conditions, renew the intake air cleaner element every 10,000 km (6,000 miles), or even more frequently if necessary

3)

normally every 40,000 km (24,000 miles), but if fuel is of poor quality every 20,000 km (12,000 miles)

4)

Renew Poly-V-belt every 40,000 km (24,000 miles)

5)

After 60,000 km (36,000 miles), change the maintainance free Poly-V-belt, do not adjust

*)

invoiced as a separate item

BMW AG Motorcycle Division

Maintenance Schedule

R1100RT/R1100RS/R850GS/R1100GS/R 850R/R1100R

Order No. 01 71 7 654 296 UX-VS-2, 03.99 Printed in Germany

Customer Registration No.

Order No. Signature of mechanic

BMW

Pre-delivery check

Inspect crates on receipt for signs of damage

Motorcycle:

– unpack

– check scope of delivery

– install/complete

– clean

Battery:

– remove

– add battery acid

– charge

– grease the terminal posts

– re-install (mark date)

Check complete specification delivery:

– tools

– handbooks and documents

– keys

– optional extras

Check headlight (basic setting), adjust if necessary

Check front and rear wheel brake fluid levels

Check torque setting of the rear wheel retaining studs

Check tyre pressure

Check engine oil level, top up if necessary

Fuel the motorcycle

Check basic clutch setting, adjust if necessary

Safety/operating check as final inspection:

– idle speed

– clutch, gear shifting

– steering

– front and rear brakes

– telltale and warning lights, instruments, lighting and signalling equipment

– ABS

– test ride, if necessary

BMW AG Motorcycle Division

Pre-delivery check

R1100RT/R1100RS/R850GS/R1100GS/R 850R/R1100R

B

Order No. 01 71 9 799 171 UX-VS-1, 7/95 Printed in Germany

Designation Data Measuring unit or

specification

Oilcapacities

Engine (incl. filter)

Engine (without filter renewal)

Gearbox

Rear wheel drive

3.75

5.50

fresh fill 1.0

change 0.8

fresh fill 0.25

change 0.23

litre

[SI 11 048 90]

Brand-name HD oil for

petrol engines of API classi-

fication SE, SF, SG;

combination with CC or CD

specification

litre

Valve clearance

measured cold, i.e. at max. 35 °C

E 0.15 / A 0.30 mm

Ignition

Static ignition

disconnect at

6° b TDC

Spark plugs

Electrode gap

limit of wear

Bosch FR5DTC

0.8

1.0

mm

Engine idle speed 1000 +150 1/min

CO value (without catalytic converter) 1.5 ±0.5 Vol %

Cable adjustment

for increased cold starting speed (without cable junction)

(with cable junction)

throttle (without cable junction)

gas cable (one piece)

connecting cable

throttle (with cable junction)

gas cable (one piece)

junction cable

< 1

no backslash

ca. 0.5

no backslash

ca. 0.5

no backslash

mm play

Clutch cable adjustment

wire cable at handle bar lever

at lever

12.0

7.0

mm thread

mm play

Tyre pressure

depending on load and speed

front: 2.2 – 2.5

rear: 2.5 – 2.9

bar

Tightening torques:

Oilfilter

Engine oil drain plug

Gearbox oil drain plug

Rear wheel drive oil drain plug

Locknut valve adjustment

Cylinder head cover

Generator to bracket

Tension multiple ripped belt (Poly-V)

Spark plugs

Fuel tank to rear frame

Fuel pump to tank

Adjustable handle bars

Quick release axle thread (axial)

Quick release axle clamp

Brake caliper

Bearing bolt swingarm to gearbox/rear axle

Idler bearing pin on swinging arm on gearbox/rear wheel drive

Locknut

Rear wheel retaining studs

Tube clips to air intake pipe

Screw connect. spring strut on control arm (RS with slide bearing)

Tighten cylinder head

– M 10 screw

11

32

23

8

20

8

20

22

6

20

30

22

front / rear 40

150 (Loctite 2701)

7 (Loctite 2701)

105 (Loctite 2701)

105

2

43

Thighten 20

180

40

Nm

Nm (clean thread)

Nm

Nm (8.8 screw)

Nm

° Torsion angle

Nm

BMW AG Motorcycle Division

Service Data

R 1100 RT/R 1100 RS/R 1100 GS/R 1100 R/R 850 R

00.1

Contents Page

00

Tightening torques R 1100 RS / R 1100 RT ....................................................................3

Tightening torques R 850/1100 GS und R 850/1100 R ...........................................12

Operating materials ...................................................................................................................21

Key to maintenance intervals ...................................................................................................22

Change engine oil, renew oil filter element .................................................................22

(Inspection I, II, III, IV) ........................................................................................................................22

Change the oil in the gearbox and rear wheel drive ...............................................23

(Inspection I, III, IV) ............................................................................................................................23

Changing oil in gearbox .............................................................................................................23

Changing oil in rear wheel drive .............................................................................................23

Checking battery acid level/topping up if necessary, cleaning/greasing

battery posts .................................................................................................................................24

(Inspection III, IV) ...............................................................................................................................24

Renewing air cleaner ...............................................................................................................24

(Inspection III) ....................................................................................................................................24

Renewing fuel filter ...................................................................................................................25

(Inspektion III) ....................................................................................................................................25

Checking/renewing spark plugs ........................................................................................29

(Inspection II, III) ................................................................................................................................29

Taking up slack at cylinder heads ....................................................................................29

(Inspection I) ......................................................................................................................................29

Checking/adjusting valve operating clearances ......................................................30

(Inspection I, II, III) .............................................................................................................................30

Adjusting Poly-V belt ................................................................................................................31

(Inspection I, II, III) .............................................................................................................................31

Renewing Poly-V belt

(40 000 km/24 000miles) ..........................................................................................................31

(renew maintenance-free belts every 60 000 km/36 000 miles) .........................................................31

Checking brake pads and discs for wear/renewing ...............................................32

(Inspection III) ....................................................................................................................................32

(ABS: Inspection II, III) .......................................................................................................................32

00 Maintenance and general instructions

00.2

Contents Page

Checking brake pads for wear ................................................................................................32

Renewing brake pads – front brake ......................................................................................32

[RS] Renewing brake pads - rear brake ..............................................................................33

[GS/R/RT] Renewing brake pads - rear brake .................................................................33

Checking brake discs for wear ...............................................................................................33

Checking brake fluid level/topping up ............................................................................33

(Inspection III) ....................................................................................................................................33

Bleeding/renewing the brake fluid using the handbrake lever/

brake pedaln .................................................................................................................................34

(Inspection III, IV) ...............................................................................................................................34

Bleeding front brake circuit/renewing fluid ........................................................................34

Bleeding rear brake circuit/renewing brake fluid ............................................................34

Grease the centre stand [RS], side stand and clutch cable nipple ................35

(Inspection II, III, IV) ...........................................................................................................................35

[RS] Cleaning and greasing the windshield adjusting shaft ...............................35

(Inspection III) ....................................................................................................................................35

[RS] Grease front suspension strut at its lower attachment lug

(version with plain bearing only)

........................................................................................35

(Inspection II, III) ................................................................................................................................35

Checking/adjusting clutch operating clearance ......................................................36

(Inspection I, II, III) .............................................................................................................................36

Checking tightness of rear wheel studs ........................................................................37

(Inspection I) ......................................................................................................................................37

[RS] Check tightness of screws at adjustable handlebar ....................................37

(Inspection I) ......................................................................................................................................37

[R] Check steering damper ...................................................................................................37

(Inspection II, III) ................................................................................................................................37

Taking up slack on hose clips at intake stub pipen ................................................37

(Inspection I, III) .................................................................................................................................37

Checking front wheel bearings/

checking tilt play at rear wheel ..........................................................................................37

(Inspection III) ....................................................................................................................................37

Checking swinging arm bearings, adjusting if necessary ...................................37

(Inspection I, II, III) .............................................................................................................................37

Checking/adjusting throttle synchronisation and CO emission value ..........38

(Inspection I, II, III, IV) ........................................................................................................................38

Final inspection with road safety and functional check .......................................42

(Inspection I, II, III, IV) ........................................................................................................................42

00.3

00

Tightening torques R 1100 RS / R 1100 RT

Model R 1100 RS R 1100 RT

11 Engine

Connection Nm Nm

Cylinder head

Tightening sequence:

1. Tighten cylinder head nuts (oiled) crosswise 20 20

1.1 Tighten all nuts to correct torque for joint

1.2 Tighten all nuts to correct angle 90°

1.3 Tighten all nuts to correct angle 90°

2. M 10 screw 40 40

3. M 6 screw 9 9

After 1000 km, tighten cylinder head nuts crosswise:

1. Unfasten one nut

2. Tighten one nut to initial value 20 20

3. Tighten nut to wrench angle 180°

4. Unfasten/retighten M10 screw 40 40

Bearing cap on rocker shaft 15 15

Locknut on valve clearance adjusting screw 8 8

Cylinder head cover to cylinder head 8 8

Camshaft end cover to cylinder head 9 9

Air intake connection to cylinder head 9 9

Camshaft

Chain sprocket to camshaft 65 65

Camshaft bearing cap 15 15

Rotary breather

Vent line to alternator mount cover

M 8 screw 20 20

Banjo screw 25 25

Alternator mount cover

M 6 screw 9 9

M 8 screw 20 20

Auxiliary shaft

Chain sprocket to crankshaft 10 10

Chainwheel to auxiliary shaft 70 70

Chain tensioner housing to engine block 9 9

00.4

11 Engine

Connection Nm Nm

Oil filter

Oil filter 11 11

Oil drain plug 32 32

Oil pump

Mesh filter basket to engine block 9 9

Oil pump cover 9 9

Pressure relief valve 35 35

Oil pressure switch 30 30

Oil cooler

Oil cooler pipe to engine block 10 10

Cooling oil line - banjo screw 25 25

Cooling oil line - banjo screw with oil vent valve 25 25

Oil lines to oil cooler 25 –

Oil cooler to holder 9 9

Oil cooler return line to engine block 35 35

Oil cooler feed line to frame 20 20

Oil cooler feed line to engine block 25 25

Screw-in union for oil cooler connection at

engine block

35 35

Clean threads and apply Loctite 603 to inner and

outer threads and in the contact face area

Oil cooler hose at oil thermostat – 40

Cylinders

Tightening sequence

M 8 screw 20 20

M 6 screw 9 9

Chain guide rail pivot screw 18 18

Timing chain

Chain tensioner 32 32

Connecting rod

Big end cap Joint torque 20 20

Additional wrench angle 80°

Crankcase

Tightening sequence:

M 10 screw (oiled) 45 45

M 8 screw (oiled) 20 20

M 6 screw 9 9

Model R 1100 RS R 1100 RT

00.5

12 Engine electrical system

Connection Nm Nm

Starter motor to engine 20 20

Starter cover to gearbox housing 7 –

Positive lead to starter motor 10 10

Alternator to alternator support cover 20 20

Tensioning and retaining strap at alternator 20 20

Spacer at alternator 20 20

Positive lead to alternator 15 15

Belt pulley at alternator 50 50

Belt pulley to crankshaft 50 50

Poly-V belt preload 8 8

Spark plug 20 20

13 Fuel preparation and control

Temperature sensor on engine block 25 25

16 Fuel tank and lines

Fuel tank to rear frame 22 22

Fuel pump assembly to tank 6 6

18 Exhaust system

Muffler to footrest 35 35

Manifold to cylinder head (with strap) 22 22

(with jacket pipe) 18 18

Muffler to support plate for center stand 20 20

Clip on muffler 50 50

Grease clamping face with Never Seez

Oxygen sensor (lambda probe) to muffler 55 55

Grease with Never Seez

Model R 1100 RS R 1100 RT

00.6

21 Clutch

Connection Nm Nm

Clutch housing Joint torque 40 40

oil screw threads lightly

Additional wrench angle 32°

Housing cover 18 18

Locknut on release lever 22 22

23 Gearbox

Oil filler plug 23 23

Oil drain plug 23 23

Gearbox cover to gearbox housing 9 9

Screw for neutral detent 13 13

clean thread + Loctite 243

Oil guide plate at gearbox housing 9 9

clean thread + Loctite 573, also apply Loctite 573

to sealing face between oil baffle plate and gear-

box housing

Gearbox to engine block 22 22

Clutch lever to gearbox housing 18 18

Selector lever to selector shaft 9 9

Pedal to footrest plate 35 18

Model R 1100 RS R 1100 RT

00.7

31 Front fork

Connection Nm Nm

Clamp between fixed tubes and fork bridge 22 –

Screw connection between fixed tube and

fork bridge

– 45 (free from oil and

grease)

Control arm to ball joint 130 130

clean thread + Loctite 2701

Fork bridge to ball joint 130 –

clean threads

+ Loctite 2701

–

Threaded journal to frame – 130

– clean threads

+ Loctite 243

Ball joint to fork slider tube bridge 230 230

Frame 230 –

Slider tube bridge to slider tube 22 –

clean thread

+ Loctite 243

–

Screw plug to fixed fork tube 18 pressed fit,

do not release

Clamping screws, quick-release axle 22 22

Control arm to engine right 73 73

Screw cap left 42 42

apply light coat of Never Seez to thread

Spring strut to frame 47 47

Spring strut to control arm 43

8.8 screw

43

8.8 screw

50

10.9 screw

50

10.9 screw

32 Steering

Handlebar at rubber mount 40 –

Rubber mount at fork bridge 40 –

Handlebar to fork bridge – 21

Twistgrip to handlebar 7 7

Handlebar weight to fixed handlebar 20 –

Handlebar weight to handlebar – 20

Handlebar weight to adjustable handlebar 7 7

clean threads

+ Loctite 2701

–

Model R 1100 RS R 1100 RT

00.8

33 Rear wheel drive

Connection Nm Nm

Oil drain plug 23 23

Oil filler plug 23 23

Threaded ring 118 (Hylomar SQ 32 M) 118 (Hylomar SQ 32 M)

Hexagon nut, input bevel gear 200 200

clean thread + Loctite 273

Housing cover 35 35

Fixed bearing journal

Swinging arm to gearbox/

Swinging arm at rear wheel drive

150 150

clean thread + Loctite 2701

Free bearing journal

Swinging arm to gearbox/

Swinging arm at rear wheel drive

77

clean thread + Loctite 2701

Locknut on free bearing journal 105 105

clean thread + Loctite 2701

Strut at rear wheel drive / gearbox 43 43

load motorcycle with approx. 85 kg and tighten

loose strut

Spring strut to rear frame / rear swinging

arm

43

8.8 screw

43

8.8 screw

50

10.9 screw

50

10.9 screw

Hydraulic spring adjuster at footrest plate – 22

Model R 1100 RS R 1100 RT

00.9

34 Brakes

Connection Nm Nm

Brake caliper to slider tube 40 40

Brake caliper to rear wheel drive 40 40

Brake disc to front wheel 21 21

Brake disc to rear wheel drive 21 21

clean thread + Loctite 273

Brake hose to brake caliper, front/rear 15 15

Brake hose to fitting 15 15

Brake hose to flow distributor 15 15

Flow distributor to frame 9 9

Flow distributor to slider tube bridge 9 9

Flow distributor to holder/slider tube – 9

Bleed screw on front brake caliper 7 7

Bleed screw on rear brake caliper 7 4

Master cylinder to footrest plate 9 9

Brake pedal to footrest plate 37 37

Handbrake lever pivot pinl 8 8

the Tuflok blue thread retaining agent can be

slackened off and tightened several times if nec-

essary

ABS sensor 4 (handtight) 4 (handtight)

ABS unit to holder

M6 screw 9 9

M6 screw (Torx) 5 5

Brake line to ABS unit 15 15

Bleed screw to ABS unit 9 9

36 Wheels and tyres

Clamping screws, quick-release axle 22 22

Screw connection, quick-release axle 30 30

Screw on wheel nuts handtight, then tighten

crosswise:

Initial tightening 50

105

50

105

Final tightening

Model R 1100 RS R 1100 RT

00.10

46 Frame

Connection Nm Nm

Rear frame to gearbox/engine 47 47

Screw connection on right of gearbo

at right of engine

at left of engine

at left of gearbox

Footrest plate to gearbox 22 22

Frame to engine 82 82

Struts to frame 47

8.8 screw

47

8.8 screw

58

10.9 screw

58

10.9 screw

Struts to engine 47 47

Guard hoop to cylinder head 20 20

Side stand to pivot mount 42 42

clean thread + Loctite 2701

Center stand to carrier plate 21 21

clean thread + Loctite 2701

Carrier plate for center stand to engine block

M12 screw 72 72

clean thread + Loctite 2701

M 8 screw (countersunk) 21 21

clean thread + Loctite 2701

Grab handle to rear frame 9 9

Lifting handle to rear frame 10 10

Footrest plate to rear frame

M 6 screw 9 –

M 8 screw 21 21

M 10 screw 42 –

Footrest to footrest plate 42 –

Fairing support bracket to frame 20 20

Model R 1100 RS R 1100 RT

00.11

51 Equipment

Connection Nm Nm

Ignition/steering lock to fork bridg 15 15

61 General electrical system

Horn to horn bracket 8 20

Ground (earth) strap to engine block 10 10

Rubber bushing for battery holder at gearbox 4 4

Model R 1100 RS R 1100 RT

00.12

Tightening torques R 850/1100 GS und R 850/1100 R

Model R 850/1100 GS R850/1100R

11 Engine

Connection Nm Nm

Cylinder head

Tightening sequence:

1. Tighten cylinder head nuts (oiled) crosswise 20 20

1.1 Tighten all nuts to correct torque for joint

1.2 Tighten all nuts to correct angle 90°

1.3 Tighten all nuts to correct angle 90°

2. M 10 screw 40 40

3. M 6 screw 9 9

After 1000 km, tighten cylinder head nuts crosswise:

1. Unfasten one nut

2. Tighten one nut to initial value 20 20

3. Tighten nut to wrench angle 180°

4. Unfasten/retighten M10 screw 40 40

Bearing cap on rocker shaft 15 15

Locknut on valve clearance adjusting screw 8 8

Cylinder head cover to cylinder head 8 8

Camshaft end cover to cylinder head 9 9

Air intake connection to cylinder head 9 9

Camshaft

Chain sprocket to camshaft 65 65

Camshaft bearing cap 15 15

Rotary breather

Vent line to alternator mount cover

M 8 screw 20 20

Banjo screw 25 25

Alternator mount cover

M 6 screw 9 9

M 8 screw 20 20

Auxiliary shaft

Chain sprocket to crankshaft 10 10

Chainwheel to auxiliary shaft 70 70

Chain tensioner housing to engine block 9 9

Page is loading ...

BMW R 1100 GS + Adventure, R 1100 R, R 1100 RS, R 1100 RT, R 850 GS + Adventure, R 850 R, R 850/1100 R User manual

Related papers

Other documents